Curb system apparatus and method therefor

ABSTRACT

Disclosed herein is a system and method for a seamless curb system suitable for a sanitary environment. The structural material has a substantially uniform cross section. The structure is preferably formed of concrete as is used in traditional curb systems. An outer shell is provided which provides a permanent form for containing the structural material. In the preferred embodiment, the outer shell is formed of stainless steel. The elements are sealed to each other in an end to end relationship and along the floor a sanitary environment. At least one anchor is disposed in a slot in the floor of the sanitary environment to locate the curb system.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation-in-part of U.S. patent application Ser. No. 12/291,503, filed Nov. 9, 2008, entitled “curb system apparatus and method therefor,” now issued as U.S. Pat. No. 7,815,392.

FIELD OF THE INVENTION

The present invention relates to curb systems for containment barriers in industrial environments. More specifically, the present invention relates to a curb system suitable for creating a containment barrier in a sanitary environment.

BACKGROUND OF THE INVENTION

It is well known to use a concrete curb in a plant environment to protect walls against damage from equipment such as a fork lift truck. Typically, concrete curbs are poured on-site using forms to hold the concrete in place as it cures. In the process of pouring the concrete for the curbs significant mess is left behind at the job site. The process of producing curbs on-site with forms also causes in interruption in other construction or preparation activities within the plant. In addition, the poured curbs take days to cure before the forms can be removed and the construction is complete. The longer that labor is present on the job site, the higher the cost.

It is also well known to manufacture a curb off-site and transport pre-formed curbs for installation on site. Concrete curbs have high compression strength, but low tensile strength, and may crack or break during transportation. Additionally, concrete curbs are very heavy, resulting in higher transportation and labor costs. Lastly, installation on site of pre-formed concrete curbs, as well as poured concrete curbs, lead to gaps between the top of the curb and wall, creating a region where water can settle and contaminants, including bacteria, may grow.

One substitute for concrete is found in U.S. Pat. No. 7,407,341, which discloses a floating barrier wall that includes a number of individual barrier units each comprising a housing formed in the general shape of a highway barrier having a top wall, a bottom wall, opposed end walls, and, opposed side walls interconnected to form a hollow interior which is preferably partially or completely filled with a foam material. A ballast weight is secured to each barrier unit, either along or beneath the bottom wall, to maintain the barriers in an upright position in the water. Cables, couplers and/or other connectors are employed to mount adjacent barrier units end-to-end to form a barrier wall which can encircle a vessel or otherwise isolate an area within a seaport to provide security. Clearly, the above invention, although formed of a cellular structure, does not disclose a curb system for protecting a wall in a plant environment or a means of sealing.

U.S. Pat. No. 4,963,408 discloses a unitary composite laminate structure which comprises an inner foam core and an outer encapsulating layer with a high strength, load-bearing matrix. The above invention discloses a wall structure rather than a curb system and does not disclose a sanitary solution for protecting a wall in a plant environment.

U.S. Pat. No. 7,351,002 discloses a barrier device comprises a top wall, a bottom wall, opposed end walls and opposed side walls interconnected to form a hollow interior in which a pair of spaced openings are formed which extend between the side walls. An external reinforcement structure is provided to enhance the structural integrity of the barrier device, including first and second beams each located along one of the side walls which are connected to one another by a mounting device extending through the openings in the hollow interior, or, alternatively, are mounted within a seat formed in each side wall between the opposed ends of the barrier device. The beams of one barrier device are connected end-to-end with the beams of adjacent barrier devices to form an essentially continuous wall of barriers which resist disengagement from one another and exhibit improved resistance to being broken apart upon impact by a vehicle. Although formed of a cellular structure, does not disclose a curb system for a plant environment or a means of sealing the curbing system.

U.S. application number 20080041004 discloses a structure having multiple layers of polymer foam for forming structural concrete into a desired planar shape that retains a foam panel when flat or upright, providing an integrated air gap between concrete panels. The polymer foam has a planar shape and an exterior surface with multiple channels into the panel. Then concrete is poured upon the exterior surface and into the channels. Although the above application discloses using foam between wall panels, it does not provide a sanitary solution.

U.S. application number 20070157538 discloses a modular curb assembly of pre-cast pre-finished components forming a base for supporting sidewalls of a shower stall or other enclosure attached to a floor. The curb is made from a plurality of pre-cast pre-finished components of substantially uniform shaped cross section joined in end to end relationship to each other and attached to a floor in a predetermined contour around the perimeter of the enclosure. The components may be straight, curved or in the shape of angular corners and are cast in various configurations which provide a choice of different end angles so that the contour of the curb can be varied depending upon which different combination of component configurations are used in any particular curb design. Although these curb elements are used in association with shower walls, they are neither sanitary nor are they protective of the shower walls.

U.S. application number 20050284055, discloses a protective baseboard for protecting a building wall in an industry having sanitary requirements. This baseboard employs a stainless steel casing having apertures for filling the casing with a filler material. The casing may be fastened to the floor by a bracket bolted to the floor.

Thus, there is a need in the art to provide a containment barriers for a sanitary environment. Further it is desirable to provide a low cost curbing system that is durable and inexpensive while maintaining a sanitary, seamless environment. It is further desirable to provide a curb system that is fast to install while proving little interruption to ongoing operations within the facility.

SUMMARY OF THE INVENTION

A sanitary curb system for creating a containment barrier comprises a plurality of modular curb elements having a base, a back, a top, a face, and ends, where the elements are adapted to be disposed adjacent to a floor. The elements are sealed to each other in an end to end relationship to form a seamless containment barrier. Each of the elements comprises a shell forming at least a face of the curb element, where the shell is adapted to receive structural material therein. A downwardly extending forward anchor is disposed adjacent to the face of the shell, the anchor is at least partially disposed within a slot in the floor to position or locate the element or shell. A seal is disposed between the forward anchor and the floor. The forward anchor may extend from the face of the shell.

The shells of the sanitary curb system are sealed to each other in an end to end relationship. The shells may further include a cove that extends from the face and the forward anchor may extend from the cove. The shell is formed of stainless steel.

The curb system may include a plurality of rearwardly extending brackets. The shells may be disposed adjacent to a wall to permit the brackets to be fixedly attached to the wall. The shells may also be disposed in a back to back relationship to form a pier. The structural material may be concrete.

A method of constructing an energy absorbing curb system for protecting an interior wall of a facility requiring a sanitary environment comprises the steps of providing a slot in the floor to accept a forward anchor and providing a plurality of modular curb elements having a base, a back, a top, a face, and ends, the elements adapted to be disposed adjacent to the floor. The elements are sealed to each other in an end to end relationship to form a seamless containment barrier. Each of said elements comprises a shell forming at least a face of the curb element, where the shell is adapted to receive structural material therein. A downwardly extending forward anchor is disposed adjacent to the face of the shell, where the anchor is at least partially disposed within the slot in the floor to position the element.

The method further includes providing a seal between the forward anchor and the floor and positioning the elements on the floor by inserting the forward anchor into the slot and sealing the elements to each other in an end to end relationship. Finally filling the shell with a structural material and providing a seal between a top channel and the wall.

Further objects, features and advantages of the present invention will become apparent to those skilled in the art from analysis of the following written description, the accompanying drawings and the appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an environmental view of the curb system for protecting a wall and creating a seal according to the principles of the present invention;

FIG. 2 is a perspective view of a curb element disposed adjacent to a wall, according to the principles of the present invention;

FIG. 3 is a cross-sectional perspective view of one embodiment of a curb element according to the principles of the present invention;

FIG. 4 is an illustration of a cross-sectional perspective view of one embodiment of a curb element according to the principles of the present invention, showing one example of a rear anchor and a cove;

FIGS. 5 a through 5 g reveal alternative embodiments of the curb system of the present invention;

FIG. 6 a is a perspective view of a shell according to an alternate embodiment of the present invention;

FIG. 6 b is a perspective view of the shell of FIG. 6 b, revealing rearwardly extending brackets; and

FIG. 7 is a cross-sectional view of an alternate embodiment of the curb system of the present invention incorporating two shells back to back to form a pier.

DESCRIPTION OF THE PREFERRED EMBODIMENT

The present invention incorporates shells that are located in the facility floor by anchors along the length of the curbs. The anchors locate the curb system by being positioned into slots cut into the floor of the facility. The shells replace forms and become a permanent part of the curb system.

With initial reference to FIG. 1, an environmental view of the curb system 5 for protecting a wall 1 and creating a seal according to the principles of the present invention is shown. In an environment such as a manufacturing facility, especially a plant processing food, drugs, and medical devices, sanitation is essential. One advantage of the present invention is to provide a seal between the floor 2 and the curb system 5 and the walls 1 and curb system 5. The curb system 5 is comprised of a plurality of pre-fabricated, modular curb elements 10 formed of a structural material such as multicellular structure or concrete. Although a multicellular structure or concrete is disclosed as types of structural material, those skilled in the art will immediately recognize that any suitable substitute may be employed that may be easily transported or poured into the shell system. In the preferred embodiment, the structural material is concrete because of its cost advantages over a multicellular or foam structure. Accordingly the system 5 may reduce damage to a wall resulting from the accidental collision with a plant vehicle, such as a fork lift truck 3.

Referring now to FIG. 2, a perspective view of one of a plurality of pre-cast modular curb elements 10 of the curbing system 5 according to the principles of the present invention is shown. Each of the curb elements 10 is adapted to be disposed adjacent to the wall 1 and floor 2. The core and energy absorption characteristics of curb element 10 is achieved by a structural material 30, having a base 15, a front 17 and a top 19, and first and second ends 21, 22 separated by a length 23. The curb elements 10 are sealed to each other in an end to end (21 to 22) relationship to form a seamless containment barrier 5 to the wall 1. The curb elements 10 are comprised of the structural material 30 and an outer shell 20 disposed over at least a portion of the front 17 of the structural material 30. In the preferred embodiment the outer shell 20 is formed of stainless steel.

Each curb element 10 comprises a structural material 30 encapsulated by an outer shell 20 to provide impact resistance and stability. This engineered solution is easy to install and highly durable.

In the preferred embodiment, each of the curb elements 10 has a slope 16 intersecting the top 19 and face 17 and the shell 20 covers the top 19, slope 16 and face 17. A front channel 11 is disposed below the face and is provided for at least partially anchoring the element 10 when installed with an integral cove and flooring system.

Referring now also to FIG. 3, a cross-sectional perspective view of one embodiment of a curb element 10 according to the principles of the present invention is shown revealing the operative elements therein. The base 15 of the curb element 10 is adapted to be disposed adjacent to a floor 2. The present embodiment of the curb element 10 has a back 18 adapted to be disposed adjacent to a wall 1. So as not to be limiting, the curb element 10 is described in several embodiments and as discussed further below, the present invention may be adapted to receive a wall 1 upon the top 19 of the curb element 10. The front channel 11 is shown traversing the length 23 of the curb element 10 to provide a surface to receive a cove or front anchor (not shown). A rear channel 12 is disposed within a back 18 of the element 10 for receiving a rear anchor. The rear channel 12 provides a recess to enable the anchor to mount flush against the element 10. A top channel 13 is provided to enable the element 10 to receive a seal along the top of the curb adjacent to the wall 1.

In the present embodiment, the structure 30 has a substantially uniform cross section defined by a base 15, the back 18, top 19, slope 16 and front portion 17. Although multiple cross sections are conceivable, the present cross section is provided for exemplary purposes.

In the preferred embodiment, sealing is provided by polyurethane, and ideally, an antimicrobial sealant would be employed. Although not shown, one method for installation of multicellular curb elements 10 is to cut the element 10 on a 45 degree bevel and to use 8″ biscuits to align and secure the sections and to seal the end to end sections with a sealer. It is intended to be within the spirit and scope of the present invention to provide pre-cast modular curb elements for interior and exterior corners at various angles or radiuses as well as ramp angles.

In addition, it is contemplated to use rebar (not shown) vertically disposed within the floor 2 to secure and hold down the curb elements 10 if necessary. The rebar may be threaded, as an example, enabling the curb elements to be downwardly secured by a threaded fastener, nut and washer or by any suitable means known in the art.

In the present embodiment, the pre-fabricated, modular curbing system 10 of the present invention is comprised of a hi-density, energy absorbing, expanding polypropylene foam encapsulated in an outer shell of either stainless steel or a polyurea/polyaspartic reinforced coating. This engineered solution is lightweight, yet highly durable, with technology similar to bumper systems used in cars and trucks. It should be noted that it is contemplated to be within the spirit and scope of the present invention to substitute other light weight energy absorbing materials for high density foam or polypropylene foam, including, but not limited to other thermoplastics foams, such as polyethylene foam, latex foam, natural materials or other man made materials.

One intended application of the curb system 10 of the present invention is for plant and laboratory environments where transportation vehicles are employed, such as beverage refrigeration rooms, formulation labs, or pharmaceutical manufacturing facilities. The present invention may be employed anywhere that structural integrity and sanitation are essential.

Referring now also to FIG. 4 an illustration of a cross-sectional perspective view of one embodiment of a curb element 10 according to the principles of the present invention reveals one example of a rear anchor 41 and a cove 42. The curb element 10 is installed by first providing a channel, key or slot in the floor parallel to an intended axis of the curb element 10. In the preferred embodiment, a stainless steel anchor 41 is first inserted into the slot and then a bed of sealer is applied to the anchor 41 and the floor portion below the base 15. The rear anchor 41 is at least partially disposed within a slot in the floor 2. A sealant 50 is applied to the rear anchor 41 and floor 2 beneath the base 15. The curb element 10 is then set into the sealant 50. After positioning the curb element 10, sealant 50 is provided in the top channel 12 to provide a seal between the wall 1 and the curb element 10. In the present embodiment, the front anchor is a cove 42 integral to a sanitary floor covering, such as the superior floor covering material Sanicrete™ . As such, the present embodiment is described to be installed with a new sanitary flooring system. However, other embodiments, including those suitable for retrofit applications, are disclosed in FIGS. 5 a through 5 g.

Referring now also to FIGS. 5 a through 5 g, alternative embodiments of the curb system of the present invention are revealed. In each of the FIGS. 5 a through 5 g, “h” refers to height of the curb element 10 and “w” refers to the width of the element 10. For example, FIG. 5 a is an example of a retrofit application where “s” refers to the width of the slot of which receives a boot 44 integrated within the structure 30. For a retrofit application, the floor 2 would have to be cut or formed in advance to provide a channel to receive the boot 44. A sealer is provided in the slot 43 to anchor and seal the curb system 5. In the embodiment of FIG. 5 a, the back 18 of the element 10 is adapted to be in substantial contact with the wall 1, and accordingly, a sealer would be provided in the top channel to seal the curb 10 from water penetration and bacteria growth. Another advantage of the present invention is that the dimension “h” of the curb system 5 may be as high as four feet.

Referring now to FIG. 5 c, a variation of the curb system 5 according to the present invention is shown. The curb element 10 is shown supporting a wall 1 at a top channel 12. The top channel is coated with a sealer prior to installation of the wall 1. In addition, the slots 43 are sealed along the anchors 45, which in the present embodiment are flanges extending from a stainless steel shell 20. FIG. 5 g is an example of using a cove 42 rather than a boot 44 to install a retrofit curbing system 5 according to the principles of the present invention. Another layer of sealer between the ends of the curb elements and all intersections completes this engineered seamless solution to provide an energy absorbing, durable, lightweight and hygienic application.

As such, the present invention provides the advantages of fast installation to new or existing walls with minimal invasion to operations within the facility. Additionally, low odor allows business to remain operational during installation. The curb system of the present invention is a pre-fabricated system yielding low transportation costs, fewer injuries during installation and minimal prep time. The system is ideal for retro-fitting to existing walls for a sanitary environment.

Referring now also to FIG. 6 a, a perspective view of a shell 120 according to an alternate embodiment of the present invention is shown. In the exemplary embodiment, the shell 120 is formed of stainless steel that forms a face 127 with a slope 126 extending from an upper portion of the face 127. A boot 124 or cove 124 extends from a lower portion of the face 127. The cove 124 projects outwardly from the face 127. A downwardly extending forward anchor 125 is disposed adjacent to the face 127 of the shell 120. In the preferred embodiment, the forward anchor 125 extends from the cove 124. The anchor 125 is at least partially disposed within a slot 43 in the floor 2 to position or locate the shell 120. A seal is disposed between the forward anchor 125 and the floor 2.

The curb elements 10 incorporating a shell 120 are sealed together in an end to end relationship by providing sealant to ends 111 and 112 of each shell 120 to form a seamless containment barrier 5. The shells 120 are adapted to receive structural material such as concrete. The concrete is poured into the shells which take the place of forms and remain as part of the containment barrier 5.

Referring now to FIG. 6 b, a perspective view of the shell of FIG. 6 b, revealing rearwardly extending brackets 122 and 123 is shown. A channel 128 extends from the slope 126. The shells 120 may be disposed adjacent to a wall (not shown) to permit the brackets 122, 123 to be fixedly attached to the wall. After concrete is poured into the shells, a sealant may be provided across the top of the shell 120 adjacent to the channel 128 to form a top seal. The top seal assures no moisture of bacteria will enter a containment area.

FIG. 7 is a cross-sectional view of an alternate embodiment of an element 110 of the present invention incorporating two shells 120 back to back to form a pier. The pier may support a wall 101. Prior to installation, a slot is cut in the floor of the sanitary environment where a containment barrier 5 is to be installed. The slot will determine the location of the curb system, as the forward anchor 125 is positioned in the slot. A polyurethane, and ideally, an antimicrobial sealant is provided in the slot and the shell 120 is then positioned by inserting the forward anchor 125 in the slot, thereby forming a seal 50. Concrete is filled in the shells 120 and a sealant 50 is applied across the top. Rebar 140 may be provided to further stabilize the element 110. The material 130 is preferably concrete.

Additionally, because the curb elements 10, 110 in the preferred embodiment are formed within pre-formed shells, they be installed as four foot high sections, providing more wall protection; heights impractical for traditional concrete curbs. The high-energy absorption for low- and medium-speed impact from forklifts, palette jacks, hand trucks, transportation carts, etc. increases safety within the facility and results in fewer injuries and less damage to infrastructure and equipment.

Additional advantages include chemical resistance and dimensional stability in a fluctuating thermal environment. This seamless system provides superior hygiene and anti-microbial agents to hinder bacterial growth.

A method of constructing an energy absorbing curb system for protecting an interior wall 1 of a facility requiring a sanitary environment, comprises the steps of providing a slot 43 in the floor 2 to accept a forward anchor 125 and providing a plurality of modular curb elements 10, 110 having a base 15, a back 18, a top 19, a face 127, and ends 111, 112, the elements 10, 110 adapted to be disposed adjacent to the floor 2. The elements 10, 110 are sealed to each other in an end to end relationship to form a seamless containment barrier 5. Each of said elements 10, 110 comprises a shell 120 forming at least a face 127 of the curb element 10, 110, the shell being adapted to receive structural material 30, 130 therein, a downwardly extending forward anchor 125 disposed adjacent to the face 127 of the shell 120, where the anchor 125 is at least partially disposed within the slot 43 in the floor 2 to position the element 10, 110.

The method further includes providing a seal 50 between the forward anchor 125 and the floor 2 and positioning the elements 10, 110 on the floor 2 by inserting the forward anchor 125 into the slot 43 and sealing the elements 10, 110 to each other in an end to end relationship. Finally filling the shell with a structural material 30, 130 and providing a seal between a top channel 13 and the wall 1, 101.

The foregoing discussion discloses and describes the preferred structure and control system for the present invention. However, one skilled in the art will readily recognize from such discussion, and from the accompanying drawings and claims, that various changes, modifications and variations can be made therein without departing from the true spirit and fair scope of the invention as defined in the following claims. 

1-9. (canceled)
 10. An sanitary curb system for creating a containment barrier, said curb system comprising: a plurality of modular curb elements having a base, a back, a top, a face, and ends, said elements adapted to be disposed adjacent to the floor, said elements sealed to each other in an end to end relationship to form a seamless containment, barrier, each of said elements comprising: (i) a shell forming at least said face of said curb element, said shell adapted to receive structural material therein; (ii) a downwardly extending forward anchor disposed adjacent to said face of said shell, said anchor at least partially disposed within a slot in the floor to position said element; and (iii) a seal disposed between said forward anchor and the floor.
 11. The sanitary curb system for creating a containment barrier of claim 1, further comprising a cove extending from said shell, wherein said forward anchor extends from said cove.
 12. The sanitary curb system of claim 1, wherein said forward anchor extends from said shell.
 13. The sanitary curb system of claim 1, further comprising a cove extending from said face.
 14. The sanitary curb system of claim 1, wherein said shell is formed of stainless steel.
 15. The sanitary curb system of claim 1, further comprising a plurality of rearwardly extending brackets.
 16. The sanitary curb system of claim 15, wherein said shells are disposed adjacent to a wall to permit said brackets to be fixedly attached to the wall.
 17. The sanitary curb system of claim 15, wherein said shells are disposed in a back to back relationship to form a pier.
 18. The sanitary curb system of claim 1, wherein said structural material is concrete.
 19. A method of constructing an energy absorbing curb system for protecting an interior wall of a facility requiring a sanitary environment, comprises the steps of: providing a slot in the floor to accept a forward anchor; providing a plurality of modular curb elements having a base, a hack, a top, a face, and ends, the elements adapted to be disposed adjacent to the flour, the elements sealed to each other in an end to end relationship to form a seamless containment barrier, each of said elements comprising: (i) a shell forming at least said face of the curb element, said shell adapted to receive structural material therein; (ii) a downwardly extending forward anchor disposed adjacent to the face of the shell, the anchor at least partially disposed within a slot in the floor to position the element; and (iii) a seal disposed between the forward anchor and the floor; providing a seal between the forward anchor and the floor; positioning the elements on the floor by inserting the forward anchor into the slot; sealing the elements to each other in an end to end relationship; filling the shell with a structural material; and providing a seal between a top slot and the wall. 